Dry salt therapy device with converging-diverging nozzle

This application claims the benefit under 35 U.S.C. § 119(e) to U.S. Provisional Application Ser. No. 63/304,084, entitled “DRY SALT THERAPY DEVICE,” filed on Jan. 28, 2022, which is herein incorporated in its entirety.

Disclosed embodiments are related to dry salt therapy devices.

Dry salt therapy, also known as halotherapy, is a respiratory therapy that delivers salt particles into a user's respiratory system. For nearly 200 years, dry salt therapy has been used to treat a variety of respiratory ailments including asthma, bronchitis, pneumonia, cystic fibrosis, sinusitis, and hay fever. Dry salt therapy also provides benefits related to anxiety, fatigue, and stress, as well as skin conditions such as acne, eczema, psoriasis, dermatitis, rosacea, dryness, rashes, and inflammation. Dry salt therapy can be provided using dry salt therapy devices, or halogenerators. Dry salt therapy devices may deliver salt particles to a user's respiratory system through the air.

In some embodiments, a dry salt therapy device may comprise a blower, an exhaust passage fluidly coupled to the blower, a grinding chamber configured to aerosolize salt, the grinding chamber having an aspect ratio between 4:1 and 8:1, a tip clearance between 1 mm and 5 mm, and a floor clearance between 1 mm and 4 mm. The device may further comprise a salt vent configured to fluidly couple the exhaust passage and the grinding chamber.

In other embodiments, a dry salt therapy device may comprise a blower, an exhaust passage fluidly coupled to the blower, a grinding chamber configured to aerosolize salt, and a salt vent configured to fluidly couple the exhaust passage and the grinding chamber. The device may be configured to deliver a jet of aerosolized salt to a respiratory system of a user without being in contact with the user. The jet may have a diameter of between 4 inches and 8 inches at a distance of between 2 feet and 4 feet.

In further embodiments, a dry salt therapy device may comprise a blower, an exhaust passage fluidly coupled to the blower, the exhaust passage comprising a converging-diverging nozzle including a converging section, a throat section, and a diverging section. The device may further comprise a grinding chamber configured to aerosolize salt, and a salt vent configured to fluidly couple the exhaust passage and the grinding chamber.

In still further embodiments, a dry salt therapy device may comprise a blower, an exhaust passage fluidly coupled to the blower, a flow structure disposed in the exhaust passage and configured to modify a flow of air through the exhaust passage, a grinding chamber configured to aerosolize salt, and a salt vent configured to fluidly couple the exhaust passage and the grinding chamber.

In some embodiments, a dry salt therapy device may comprise a blower, an exhaust passage fluidly coupled to the blower, a grinding chamber configured to aerosolize salt, and a salt vent configured to fluidly couple the exhaust passage and the grinding chamber, the salt vent protruding from a wall of the exhaust passage into a center of a flow of air through the exhaust passage.

It should be appreciated that the foregoing concepts, and additional concepts discussed below, may be arranged in any suitable combination, as the present disclosure is not limited in this respect. Further, other advantages and novel features of the present disclosure will become apparent from the following detailed description of various non-limiting embodiments when considered in conjunction with the accompanying figures.

Dry salt therapy devices (or halogenerators) allow users to obtain the benefits of dry salt therapy at home or another location without requiring the user to travel to a dedicated dry salt therapy facility. When used for respiratory benefits, dry salt therapy devices operate by delivering salt particles to a user's respiratory system through the air. The salt particles may be delivered indirectly by diffusing salt particles into an enclosed area, sometimes referred to as a dry salt therapy room, a dry salt therapy tent, or a dry salt therapy cave. The salt particles may also be delivered directly to the respiratory system using a mask or a nozzle, or by holding the device close to the user's face.

The size of the salt particles may affect the efficacy of the dry salt therapy treatment. For example, salt particles of 1-5 microns have been studied in the treatment of asthma and chronic obstructive pulmonary disease (COPD). A dry salt therapy device may provide salt particles of a desired size in two ways. In the first method, the salt particles may be the appropriate size before they are loaded into the device. In this case, the device may simply generate a flow of air on which to carry the pre-sized salt particles. In the second method, the dry salt therapy device may accept larger salt particles, such as granulated salt, and the device may micronize the larger particles before mixing the micronized salt into a flow of air, thereby aerosolizing the salt particles.

The benefit of this second method is that a user need not obtain salt particles that have been specially prepared or pre-micronized. Instead, a user may load a dry salt therapy device with common forms of salt such as table salt. This may reduce the costs and complexity of dry salt therapy treatment. However, the drawbacks of using the dry salt therapy device to micronize the salt include design complexities associated with building a device capable of accepting common forms of salt, micronizing the salt down to an appropriate size, and mixing the micronized salt particles into a flow of air to be delivered to a user. These design complexities may limit the particle size that may be achieved. For example, current systems may achieve a particle size of around 5 microns. However, a particle size of around 1-3 microns or around 0.5-1.5 microns may result in greater benefits to a user.

In view of the above, the inventors have recognized the benefits of using a compact grinding chamber to micronize salt particles. In some embodiments, the grinding chamber may have an aspect ratio between 4:1 and 8:1. As used herein, the aspect ratio of the grinding chamber may be defined as a ratio of a diameter of the chamber to a height of the chamber. In other embodiments, the grinding chamber may contain a grinding rotor. Furthermore, in some embodiments, a tip clearance of between 1 mm and 5 mm may be provided. As used herein, the tip clearance of the grinding chamber may be defined as a space between a tip of a blade of the grinding rotor and an interior wall of the grinding chamber. In other embodiments, a floor clearance of between 1 mm and 4 mm may be provided. As used herein, the floor clearance of the grinding chamber may be defined as a space between a bottom surface of the grinding rotor and a floor of the grinding chamber. In some embodiments, the grinding rotor may be configured to rotate at a speed between 3,000 rotations per minute (RPM) and 4,500 RPM. In some embodiments, a grinding chamber may micronize salt particles to a particle size of between 0.5 microns and 1.5 microns.

Dry salt therapy devices may deliver salt particles, whether pre-micronized or micronized by the device, to a user's respiratory system in two ways. First, the device may disperse salt into the surrounding atmosphere, diffusing salt through the space around the device. This may be done in a dedicated space or enclosure. Such enclosures are sometimes referred to as salt rooms or salt tents. The second method of delivery requires the device to deliver the salt particles directly to the user's respiratory system. Such devices may use masks, which must be attached to the user's face, thereby restricting the user's movement during a dry salt therapy session. Other such devices may discharge a narrow stream of aerosolized salt. However, these devices must be held by the user (or another person) to ensure that the narrow stream is delivered to the correct area (i.e., the user's nose and/or mouth).

In view of the above, the inventors have recognized the benefits of a dry salt therapy device that delivers a jet of aerosolized salt to a user's face from a distance away from the user. Such devices do not require the user to be connected to or in contact with the device, allowing the user to move freely during a dry salt therapy session. In some embodiments, the jet may have a diameter of between 4 inches and 8 inches at a distance of between 2 feet and 4 feet.

In some embodiments, a dry salt therapy device may comprise one or more housing modules, a device air inlet, a blower, an exhaust passage, a device outlet, a salt vent, a grinding chamber, and a grinding chamber air inlet. In operation, a dose of granulated salt may be loaded into the grinding chamber and the device may be powered on. Powering on the device may cause the motor to micronize or aerosolize the granulated salt by turning the grinding rotor, and may cause the blower to activate. Activation of the blower may generate a flow of air through the blower. Air may enter the dry salt therapy device through the device inlet, and may be drawn through the blower into the exhaust passage. The exhaust passage may contain a salt vent that may be fluidly coupled to the grinding chamber, thereby allowing aerosolized salt to be drawn out of the grinding chamber and into the exhaust passage in response to the flow of air passing through the exhaust chamber. The grinding chamber may have an air inlet to allow replacement air to be drawn into the grinding chamber as the aerosolized salt is drawn out through the salt vent. A jet of aerosolized salt may be delivered through the device outlet to a respiratory system of a user.

In some embodiments, the exhaust passage may comprise a converging-diverging (CD) nozzle. In such embodiments, a diameter or width of the exhaust passage may decrease through a converging section until it reaches a minimum in a throat section of the CD nozzle. Downstream of the throat section, the diameter of the exhaust passage may increase through a diverging section. The diverging section may terminate at the device outlet. In such embodiments, the salt vent may be disposed in or near the throat section. In some embodiments, the salt vent may protrude from a wall of the exhaust passage into a center of the flow of air. In other embodiments, the salt vent may be disposed in either a converging section or a diverging section of the CD nozzle.

In some embodiments, the device may include a flow structure within the exhaust passage to modify the flow of air. In some embodiments, the flow structure may be disposed in the converging section. In some embodiments, the flow structure may be disposed immediately upstream of a salt vent. In such embodiments, the flow structure may increase a pressure difference between a point in the exhaust passage and a point in the grinding chamber.

The flow structure may be formed in any geometric configuration and may be disposed at any point along the exhaust passage that produces the desired flow characteristic. For example, a flow structure may be used to increase a velocity in a flow of air at a point near the salt vent or to reduce a turbulence within the flow of air. In some embodiments, a flow structure may comprise a first teardrop body and a second teardrop body, each of the first and second teardrop bodies having a tapered end and a rounded end. The rounded ends may be axially connected by an elongate member. The flow structure may be axially aligned with the flow of air such that the tapered end of the first teardrop body points in an upstream direction and the tapered end of the second teardrop body points in a downstream direction.

The blower, the exhaust passage, the flow structure, and/or the salt vent may be configured relative to one another to produce a desired concentration or flow rate of aerosolized salt. For example, in embodiments in which the salt vent is disposed at or near the throat of a CD nozzle in the exhaust passage, the flow structure may be disposed within the diverging section to modify the flow of air prior immediately upstream of the salt vent. In this example, a flow structure may be used to accelerate the flow of air, thereby decreasing the pressure in the exhaust passage. This may result in a greater pressure difference between the exhaust passage and the grinding chamber, thereby producing a higher flow rate through the salt vent. Conversely, a flow structure may be used to decelerate the flow of air, thereby reducing the pressure difference and producing a lower flow rate through the salt vent.

The blower, the exhaust passage, the flow structure, and/or the device outlet may be configured relative to one another to control a size or strength of the jet of aerosolized salt. For example, some embodiments may use a stronger blower to deliver a jet to a greater distance. Other embodiments may include a converging nozzle in the exhaust passage and a narrow device outlet to deliver a jet that is stronger or narrower.

In some embodiments, a method of using a dry salt therapy device may include loading a dose of salt into a grinding chamber of the device, activating a motor to aerosolize the salt, activating a blower to generate at least one flow of air through the device, and positioning a user at a distance away from the device such that the device delivers a jet of aerosolized salt directly to a respiratory system of the user without the user contacting the device.

Turning to the figures, specific non-limiting embodiments are described in further detail. It should be understood that the various systems, components, features, and methods described relative to these embodiments may be used either individually and/or in any desired combination as the disclosure is not limited to only the specific embodiments described herein.

In some embodiments as shown in, a dry salt therapy devicemay comprise a base, a first module, a second module, and a third module. The modular constructions may allow for one region of the deviceto move relative to another region of the device. In this respect, in one embodiment, one module may move and/or rotate relative to another module. While the present embodiment is depicted as having three modules, any number of modules may be used to house the components of the device. Modules may be formed as a single piece, or as two pieces, or as any number of pieces that may be appropriate. Modules may be formed as separate components and fixedly attached to one another. For example, modules may be attached by snap fit, press fit or threaded fasteners such as screws or bolts. Modules may also be removably attached to one another. For example, the third modulemay be removably attached to the second moduleusing magnets or snap fits. Modules may also be movably or rotatably attached to one another. In the exemplary embodiment shown, the first modulemay be configured to rock or tilt within the base, such that the device may rotate in the directions indicated by arrow R in. In other embodiments, other modules may be configured to rock or tilt in addition to or instead of the first module.

The devicemay include a device outletconfigured to eject a jetof aerosolized salt or air if the salt has been depleted (). In embodiments which include modules as shown, the device outletmay be formed in the third module. However, the device outlet may be formed in any appropriate location on the device, as the disclosure is not so limited. The jetmay have a jet diameterwhich may vary along a distancefrom the device outlet. The devicemay be configured to produce a jethaving a desired diameterat a desired distance. For example, in some embodiments, a dry salt therapy device may be configured to produce a jet having a desired diameter at a distance greater than or equal to 6 inches, 1 foot, 2 feet, and/or any other appropriate distance from the device. Additionally, the distance may be less than or equal to 3 feet, 4 feet, 6 feet, and/or any other appropriate distance from the device. Combinations of the foregoing are contemplated including, for example, greater than or equal to 6 inches and less than or equal to 6 feet, greater than or equal to 2 feet and less than or equal to 4 feet, and/or any other appropriate combination of the foregoing. Of course, while particular ranges for the jet distance are provided above, it should be understood that other ranges both greater than and less than those noted above are also contemplated as the disclosure is not limited in this fashion.

Additionally, a dry salt therapy device may be configured to produce a jet having a desired diameter greater than or equal to 2 inches, 3 inches, 4 inches, 7 inches, and/or any other appropriate diameter at the desired distance away from the device. Additionally, the diameter may be less than or equal to 8 inches, 10 inches, 14 inches, and/or any other appropriate diameter. Combinations of the foregoing are contemplated including, for example, greater than or equal to 2 inches and less than or equal to 14 inches, greater than or equal to 4 inches and less than or equal to 8 inches, and/or any other appropriate combination of the foregoing. Of course, while particular ranges for the jet diameter are provided above, it should be understood that other ranges both greater than and less than those noted above are also contemplated as the disclosure is not limited in this fashion.

It should also be understood that any range for the jet diameter may be combined with any range for the jet distance. For example, a dry salt therapy device may be configured to produce a jet having: a diameter of greater than or equal to 3 inches and less than or equal to 14 inches at a distance of greater than or equal to 6 inches and less than or equal to 6 feet; a diameter of greater than or equal to 4 inches and less than or equal to 8 inches at a distance of greater than or equal to 2 feet and less than or equal to 4 feet; and/or any other appropriate combination of the foregoing ranges. As discussed below, various features of the devicemay be adjusted in order to achieve the desired jet characteristics.

The direction of the jetmay be controlled by positioning the deviceor by aiming the device outlet. For example, in embodiments that include rotatable modules as shown, the jetmay be directed by rotating the modules. For example, in the device of, the direction of the jetmay be controlled by tilting the first modulewithin the basein either of the directions indicated by arrow R in.

In some embodiments as shown, a grinding chamber air inletmay be open to the atmosphere in order to allow air to freely flow into a grinding chamber within the device. The grinding chamber air inletmay allow replacement air to be drawn into the grinding chamber as aerosolized salt is drawn out through a salt vent, as will be described below. For example and as shown, the grinding chamber air inletmay be formed as a channel through the second moduleto allow air to freely flow between the second moduleand the third module. However, a grinding chamber air inlet need not be positioned or configured as shown. A grinding chamber air inlet may be formed at any appropriate position and in any appropriate geometric configuration to allow air to enter a grinding chamber of the device. In some embodiments where the grinding chamber air inletis disposed as shown, removal of the third modulefrom the second modulemay allow a user to access the grinding chamber air inletmore easily. Removal of the third modulefrom the second modulemay be accomplished by removably attaching the third moduleto the second module, for example using snap fits, magnets, or any other appropriate method of removable attachment.

In some embodiments as shown, a device air inletmay be open to the atmosphere in order to allow air to freely flow into the device. For example, and as shown, the device air inletmay be formed as a series of holes in a wall of the first module. The air supplied through the device air inletultimately mixes with aerosolized salt in an exhaust passage of the device, as described herein. A device air inlet need not be positioned or configured as shown. A device air inlet may be formed at any appropriate position and in any appropriate geometric configuration to allow air to enter a grinding chamber of the device. For example, a single hole or vent in a wall of the deviceis also contemplated.

In some embodiments as shown, the devicemay include electrical components. For example, one or more buttonsmay allow a user to operate the device, for example by selecting a mode of operation, a duration of operation, a power setting, or any other feature that may be selectable by a user. Some electrical components may provide feedback or information to a user about the operation of the device. For example, a light barmay provide information to a user about a mode of operation, a duration of operation, a power setting or battery condition, or any other information that may be communicated to a user. Some electrical components may form part of a power system of the device. For example, a power jackmay be configured to receive a corresponding power cord (not shown) to provide electrical power to the device.

show the internal structure of one embodiment of the dry salt therapy device. In this embodiment, the first moduleand the second modulecooperate to house a blower. The bloweris in fluid communication with an exhaust passage, which is housed within the second moduleand the third module. The exhaust passageterminates at the device outletand contains a flow structure. The exhaust passageis also in fluid communication with a salt vent. The salt ventis a fluid passageway with a first end open to a grinding chamberand a second end open to the exhaust passageto provide fluid communication between the grinding chamberand the exhaust passage. The grinding chamberhas a grinding chamber air inletwhich is open to a surrounding environment to allow air to freely enter the grinding chamber. The grinding chamberalso has a grinding rotorconfigured to spin within the grinding chamber. The grinding rotoris coupled to a motor. In some embodiments as shown, the motorhas a rotating shaftthat is attached to a spinner. The spinnerincludes spinner magnetswhich are magnetically coupled with corresponding rotor magnets(shown in), which may be contained within the grinding rotor. During operation, the motormay cause the shaftand the spinnerto rotate. The magnetic coupling of the spinnerto the grinding rotormay cause the griding rotorto rotate in cooperation with the spinner.

A user may access the grinding chamberthrough the salt ventor the grinding chamber air inlet. For example, a user may load a dose of salt into the grinding chamberthrough the salt ventor the grinding chamber air inlet. In embodiments with modules that are removably attached, for example by magnets or snap fits, a user may also access the grinding chamberby removing the second modulefrom the first module. In such embodiments, a top portionA of the grinding chambermay be formed as part of the second module, and a bottom portionB of the grinding chambermay be formed as part of the first module. The top portionA and the bottom portionB may be removably attached, for example using a press fit, snap fit, or magnetic attachment. By removing the second modulefrom the first module, the top portionA may be removed from the bottom portionB. This may provide a user with access to the interior of the grinding chamber, including full access to the grinding rotorto maintain, clean, or replace the grinding rotor. Maintenance, cleaning, or replacement of the grinding rotormay be simplified by coupling the grinding rotorto the motoras described herein, such that the grinding rotormay be removed by decoupling the rotor magnetsfrom the spinner magnetsand lifting the grinding rotorout of the grinding chamber.

In some embodiments as shown in, the dry salt therapy devicemay include a printed circuit board (PCB)and/or other suitable control arrangement or computing device, such as a microprocessor. In one embodiment, the PCBmay be in electrical communication with various electrical components of the dry salt therapy device, including a light barand a battery. The PCBand/or microprocessor may be programmed or configured to send information to and receive information from various components of the dry salt therapy device including the light bar, the batteryor other source of electrical power, the blower, the motor, and/or any other electrical components not shown including a timer of the device or buttons which may allow a user to control or interface with the device.

In some embodiments, the PCB, microprocessor, or other computing device may be programmed to allow a user to select a therapy duration for a dry salt therapy session. The therapy duration may be influenced by various parameters, including a level of power delivered to the blower and/or the motor, a rotation speed of the motor, an output velocity of the blower, a quantity of salt loaded into the device, or any other appropriate parameter. The PCB or microprocessor may be configured to control one or more parameters influencing the therapy duration, thereby allowing a user to select a desired therapy duration. For example, in some embodiments a dry salt therapy device may have selectable therapy durations of 5 minutes, 10 minutes, 15 minutes, 20 minutes, or any combination thereof. Of course, while particular values for the therapy duration are provided, it should be understood that other therapy durations both greater than and less than those noted are also contemplated as the disclosure is not limited in this fashion.

In some embodiments as shown in, the grinding chambermay be mounted separately from the motor. The motormay be mounted within a motor mount, which may be configured to retain the motorwithin a housing module of the dry salt therapy device. The shaftmay extend through the motor mount. The motor mountmay also have one or more wallsthat may form a space to accommodate the spinner. In some embodiments as shown in, the spinnermay contain one or more spinner magnets. The spinner magnetsmay be magnetically coupled to one or more rotor magnets, such that rotation of the spinnercauses a corresponding rotation of the grinding rotor.

In other embodiments, the motormay drive the grinding rotordirectly, for example by extending the shaftinto the grinding chamberand attaching the shaftto the grinding rotor, a rotating support member, or other intermediary structure to rotatably couple the shaftand the grinding rotor. In such direct-drive embodiments, although a torque from the motor may not be delivered into the grinding chamber through magnetic coupling, the grinding rotor may still be magnetically coupled to the shaft, the rotating support member, or other intermediary structure within the grinding chamber. Retaining such magnetic coupling of the grinding rotor in a direct-drive embodiment may facilitate removal or replacement of the grinding rotor for cleaning or maintenance purposes.

In some embodiments as shown in, the grinding chambermay be shaped as a hollow disc with an interior chamber diameter Dand an interior chamber height H. An aspect ratio of the grinding chamber may be defined as the ratio of the chamber diameter Dto the chamber height H (i.e., D:H). The chamber height H may be taken as any suitable measure of height within the grinding chamber. For example and as shown, in embodiments that include an interior wallwhich curves smoothly in toward a center of the grinding chamber to form a ceiling, the chamber height H may be measured from a floorof the grinding chamber to a point on the interior wall at which the interior wall curves toward the center to form the ceiling. In other embodiments that may, for example, include a ceiling and a floor which are parallel to one another, the chamber height H may be taken as the distance between the floor and the ceiling.

In some embodiments, the grinding rotormay be spaced apart from the floorof the grinding chamberby a floor clearance F. In some embodiments, the grinding rotormay be configured to rotate within a rotor diameter Dr. The rotor diameter Dmay be smaller than the chamber diameter Dsuch that a tip of the grinding rotoris spaced apart from an interior wallof the grinding chamberby a tip clearance T.

In some embodiments, the grinding chambermay include an interface areawithin which the rotating support membermay interact with the floor, the grinding rotor, or both. The rotating support membermay interact with the floor and/or the grinding rotor directly (e.g., by contacting them) or indirectly (e.g., using various bearings, gaskets, or clearances). The grinding chambermay be configured to prevent salt from entering or accumulating in at least part the interface areaand interfering with interactions among the various components therein. In some embodiments, the grinding chamber floormay include a ring or step that may rise toward the grinding rotor. In other embodiments, the rotating support membermay include a projection or flange which may extend radially from a center of the rotating support member. In the embodiment shown, a stepof the floor may cooperate with a flangeto prevent salt from entering or accumulating in the interface areabetween the grinding rotor, thereby preventing the salt from interfering with a rotation of the grinding rotor.

The rate at which salt may be micronized or aerosolized within the grinding chamber, as well as the particle size that may be achieved therein, may be influenced by various features of the grinding chamber, including at least the aspect ratio, the floor clearance F, the tip clearance T, and a rotation speed of the grinding rotor. For example, a first embodiment of a grinding chambermay have a high aspect ratio, a small floor clearance, and a small tip clearance, while a second embodiment may have a low aspect ratio, a large floor clearance F, and a large tip clearance T. The first embodiment may leave less space between the grinding rotor and one or more interior wall of the grinding chamber. Salt particles may therefore impact either the grinding rotoror the walls more frequently in the first embodiment than in the second embodiment, resulting in faster micronization or aerosolization, as well as a smaller particle size. Additionally, the larger floor clearance F of the second embodiment may allow salt particles to fall below the grinding and accumulate there instead of being micronized or aerosolized. A third embodiment may have the same aspect ratio, floor clearance, and tip clearance as a fourth embodiment, but may have a motorthat is configured to rotate the grinding rotorat a higher rate than the fourth embodiment. The higher rotation rate may result in a shorter micronization time in the third embodiment than in the fourth embodiment.

In some embodiments, a grinding chamber may produce a particle size greater than or equal to 0.5 microns, 1 micron, 2 microns, 3 microns, and/or any other appropriate particle size. Additionally, the particle size may be less than or equal to 1.5 microns, 2 microns, 2.5 microns, 4 microns, 5 microns, 10 microns, and/or any other appropriate particle size. Combinations of the foregoing are contemplated including, for example, greater than or equal to 0.5 microns and less than or equal to 10 microns, greater than or equal to 0.5 microns and less than or equal to 1.5 microns, and/or any other appropriate combination of the foregoing. Of course, while particular ranges for the particle size are provided above, it should be understood that other ranges both greater than and less than those noted above are also contemplated as the disclosure is not limited in this fashion.

In some embodiments, a grinding chamber may begin to achieve the desired particle size in a micronization time. The micronization time may be greater than or equal to 10 seconds, 20 seconds, 30 seconds, and/or any other appropriate time. Additionally, the micronization time may be less than or equal to 40 seconds, 50 seconds, 60 seconds, 120 seconds, and/or any other appropriate time. Combinations of the foregoing are contemplated including, for example, greater than or equal to 10 seconds and less than or equal to 120 seconds, greater than or equal to 20 seconds and less than or equal to 30 seconds, and/or any other appropriate combination of the foregoing. Of course, while particular ranges for the micronization time are provided above, it should be understood that other ranges both greater than and less than those noted above are also contemplated as the disclosure is not limited in this fashion.

In some embodiments, an aspect ratio of a grinding chamber (D:H) may be greater than or equal to approximately 1.5:1, 3:1, 4:1, 5:1, 6:1 and/or any other appropriate ratio. Additionally, the aspect ratio may be less than or equal to 7:1, 8:1, 9:1, 10:1, 15:1, and/or any other appropriate distance. Combinations of the foregoing are contemplated including, for example, greater than or equal to 1.5:1 and less than or equal to 15:1, greater than or equal to 4:1 and less than or equal to 8:1, and/or any other appropriate combination of the foregoing. Of course, while particular ranges for the aspect ratio are provided above, it should be understood that other ranges both greater than and less than those noted above are also contemplated as the disclosure is not limited in this fashion.

In some embodiments, a tip clearance ((D−D)/2) of a grinding chamber may be greater than or equal to 0.5 mm, 1 mm, 2 mm, 3 mm, and/or any other appropriate ratio. Additionally, the tip clearance may be less than or equal to 4 mm, 5 mm, 6 mm, 8 mm, and/or any other appropriate distance. Combinations of the foregoing are contemplated including, for example, greater than or equal to 0.5 mm and less than or equal to 8 mm, greater than or equal to 1 mm and less than or equal to 5 mm, and/or any other appropriate combination of the foregoing. Of course, while particular ranges for the tip clearance are provided above, it should be understood that other ranges both greater than and less than those noted above are also contemplated as the disclosure is not limited in this fashion.

In some embodiments, a floor clearance of a grinding chamber may be greater than or equal to 0.5 mm, 1 mm, 2 mm, 3 mm, and/or any other appropriate ratio. Additionally, the floor clearance may be less than or equal to 4 mm, 6 mm, 8 mm, and/or any other appropriate distance. Combinations of the foregoing are contemplated including, for example, greater than or equal to 0.5 mm and less than or equal to 8 mm, greater than or equal to 1 mm and less than or equal to 4 mm, and/or any other appropriate combination of the foregoing. Of course, while particular ranges for the floor clearance are provided above, it should be understood that other ranges both greater than and less than those noted above are also contemplated as the disclosure is not limited in this fashion.

In some embodiments, a rotation speed of a grinding rotor may be greater than or equal to 1,000 RPM, 2,000 RPM, 3,000 RPM, 25,000 and/or any other appropriate ratio. Additionally, the rotation speed may be less than or equal to 3,500 RPM, 4,000 RPM, 4,200 RPM, 4,500 RPM, 50,000 RPM and/or any other appropriate speed. Combinations of the foregoing are contemplated including, for example, greater than or equal to 1,000 RPM and less than or equal to 50,000 RPM, greater than or equal to 25,000 RPM and less than or equal to 50,000 RPM, greater than or equal to 3,000 RPM and less than or equal to 4,500 RPM, and/or any other appropriate combination of the foregoing. Of course, while particular ranges for the rotation speed are provided above, it should be understood that other ranges both greater than and less than those noted above are also contemplated as the disclosure is not limited in this fashion. It will be appreciated that any appropriate type of motor (e.g., servo motors, brushed motors, brushless motors, direct drive motors, or any other appropriate motors) may be selected to produce a desired range of RPM for a given embodiment. For example, a servo motor may be used to produce 3,000-5,000 RPM in one embodiment, while a brushless motor may be used to produce 25,000-50,000 RPM in another embodiment.

In some embodiments as shown in, a grinding rotormay comprise a hub portionand one or more bladesextending radially from the hub portion. In the embodiment shown, the hub portionmay have a holeformed therein to allow the grinding rotorto cooperate with a rotating support member(shown in). In some embodiments, the rotating support memberand the shaftmay be the same element. In other embodiments as shown, the rotating support memberand the shaftmay be different elements. Still further embodiments may not include a rotating support member, and the grinding rotormay be retained axially and rotated through the magnetic coupling of the rotor magnetsand the spinner magnets.

Each of the one or more bladesmay have a first edge, a second edge, a tip portion, and a root portion. The root portionmay be the portion of the bladethat attaches to the hub portion. The root portionmay attach to the hub portionin any appropriate configuration. For example, the root portionand blademay be formed as a single piece with the hub portion. The root portionmay have one or more radii at the interface with the hub portion, or it may attach at an angle. The tip portionmay be the portion of the bladethat is furthest from the hub portion. The tip portionmay be blunt, sharp, rounded, flat, pointed or any other appropriate geometry. The first edgeand the second edgemay be on opposing sides of a length of the bladethat extends between the root portionand the tip portion. The first edgeand the second edgemay be blunt, sharp, rounded, flat, serrated, curved, angled, or any other appropriate geometry. The first edgeand the second edgemay have the same geometry or different geometries. One of the first edgeand the second edgemay be a leading edge, and the other may be a trailing edge, depending upon a direction of rotation of the grinding rotor. In some embodiments as shown in, the grinding rotormay include one or more rotor magnets. The rotor magnets may be contained in the grinding rotorby the use of adhesives, press fit, snap fit, or any other appropriate method. The rotor magnetsmay be located in the hub portion, or any other appropriate location in the grinding rotor, including a root portionof a blade. The rotor magnetsmay be configured to magnetically couple to one or more corresponding spinner magnets(shown in). The grinding rotormay be formed of plastic, metal, or any other appropriate material.

As discussed above, a shaftof the motormay be attached to a spinnerwhich is magnetically coupled to the grinding rotor, such that operation of the motormay rotate the grinding rotor. In some embodiments as shown in, the spinnermay comprise a spinner bodyand one or more spinner magnet recessesconfigured to receive spinner magnets. The spinner magnetsmay be configured to magnetically couple to one or more corresponding rotor magnets(shown in). The spinner magnetsmay be contained in the spinner recessesby the use of adhesives, press fit, snap fit, or any other appropriate method. The spinnermay also comprise a shaft holeformed in the spinner bodyto receive a shaftof a motor(shown, for example, in). The shaft holemay extend completely through the spinner body(i.e., the shaft holemay be a through-hole), or the shaft holemay extend only partially through the spinner body.